An Easy to Fill and Easy to Assemble Aerosolization Module for an Aerosol Generating System

ABSTRACT

An aerosolization module for an aerosol generating device includes a reservoir and a first cover made of a resilient material and fitted into an opening of the reservoir. The first cover forms a channel which extends from outside the reservoir to its inner volume. The channel makes it possible to fill the reservoir with vaporizable material. The aerosolization module further includes a second cover configured to be mounted on the first cover, the second cover including a protrusion configured to tightly plug the channel formed by the first cover and thereby close the reservoir when the second cover is mounted on the first cover. The aerosolization module is easy to fill and easy to assemble. A method of assembling the aerosolization module is also provided.

FIELD OF THE INVENTION

The present invention relates to an aerosolization module for an aerosol generating system.

Aerosol generating systems allow vaporization of a product, generally a liquid, often called e-liquid or e-juice. The aerosol generating system according to the invention are also commonly called vaporizers or electronic cigarettes.

More particularly, vaporization of the product is obtained, generally by heating, in an aerosolization module, also called atomizer. Aerosolization is the conversion of a substance, for example in liquid state or solid state, into particles small and light enough to be carried on the air.

Aerosol generating systems or e-cigarettes are thus portable devices comprising an electric heat source, included in an aerosolization module, that heats the product (e-liquid) to create an aerosol that the user inhales, and a battery to power the heat source.

BACKGROUND OF THE INVENTION

Several atomizer technologies and configurations are known for aerosol generating systems. Such atomizers are known as “cartomizer”, “clearomizer”, etc. They all use an electric powered heating device. A battery that is embedded in a battery module provides electric power to the heating device. The battery module and the aerosolization module can be formed as a one-piece system, but they are generally provided as separate modules.

The aerosolization module generally comprises the reservoir that is filled with product to be aerosolized by the heater. Several configurations of aerosolization module are known that make it possible to fill the reservoir with a vaporizable product.

For example, U.S. Pat. No. 10,306,929 discloses an atomizer device comprising a housing forming a reservoir. A liquid injection channel for injecting a liquid solution into the reservoir is defined in an adjusting valve provided on the housing. The adjusting valve has an opening and is movable between a first position in which the opening is aligned with the channel to allow liquid injection into the reservoir and a second position in which the opening is misaligned with the channel and closes said channel. U.S. Pat. No. 10,306,929 illustrates that complex systems are generally used to allow product injection into the reservoir and closure thereof.

Such systems are complex to produce, which increases their production cost.

The present invention aims to provide an aerosolization module that is easy to fill with a vaporizable material, is reliable, and has a simple configuration making it easy to produce and to assemble.

SUMMARY OF THE INVENTION

The present invention thus relates to an aerosolization module for an aerosol generating device comprising:

-   -   a reservoir comprising at least one wall that defines an inner         volume adapted to receive a vaporizable material, said wall         defining an opening,

wherein the aerosolization module further comprises:

-   -   a first cover made of a resilient material, the first cover         being fitted into the opening and forming a channel which         extends from outside the reservoir to the inner volume of the         reservoir, the channel making it possible to fill the reservoir         with the vaporizable material to be aerosolized;     -   a second cover configured to be mounted on the first cover, the         second cover comprising a protrusion configured to tightly plug         the channel formed by the first cover and thereby close the         reservoir when said second cover is mounted on the first cover.

The combination of the first, resilient, cover forming a channel for product injection into the reservoir with a second cover, either made of a soft or rigid material, comprising a protrusion configured to plug the channel when inserted into said channel is a simple and reliable way to close the reservoir.

The protrusion is a projecting part of the second cover which can take various shapes. It is intended to be inserted into the channel and to cooperate with the walls of the channel to form a seal.

The first cover can be made of silicone.

Silicone provides flexibility that is necessary for the fitting of the first cover in the reservoir opening. Is also provides the deformation capability of the walls of the channel that is necessary for obtaining the desired tightness by cooperation with the second cover protrusion.

The second cover can be made of silicone. This enhances tightness when the channel formed by the first cover is plugged.

The opening can be located at an opposite end to a mouthpiece of the aerosolization module.

The aerosolization module can comprise a heater assembly comprising a heater and a heater holder, the heater assembly being fastened to the reservoir.

The heater holder can comprise a through-hole aligned with the channel formed by the first cover.

In such configuration, the heater holder thus coincides with the first cover so that the channel issues into the reservoir.

The reservoir and the heater holder can form a central tube in the aerosolization module, the heater extending along the central tube.

More particularly, the heater can be installed in the central tube, can be wrapped around the central tube, or can form a portion of the central tube.

Such heater configuration corresponds to a so-called “vertical heater”, in which the heater extends from the bottom to the top (e.g. mouthpiece) of the aerosolization module.

The central tube can be formed of two sections, namely a bottom section formed by the heater holder and a top section formed by the reservoir, a seal being interposed between the bottom section and the top section.

This simplifies the production process (e.g. injection moulding) of the reservoir, and provides a reliable seal between the reservoir, where a vaporizable material is stored, and central tube where aerosolized product flows.

The central tube comprises at least one lateral hole to feed the heater with vaporizable material contained in the reservoir. The heater can be surrounded by a porous material, which regulates the flow of vaporizable material from the reservoir to the heater.

One or preferably several lateral holes distributed around the central tube allow a fluid communication between the inner volume of the reservoir and the heater. The holes are thus configured to feed the heater with vaporizable material. The porous material that surrounds the heater, and is thus interposed between the holes and the heater, can absorb the vaporizable material contained in the reservoir, e.g. a vaporizable liquid. The porous material can be cotton. More particularly, it can be a cotton pad wrapped around the heater.

The porous material helps to distribute the vaporizable material around the heater.

The first cover and the second cover can define a path for providing air to the central tube.

This path can issue on a lateral wall of the aerosolization module, or on the surface of the second cover. The air is made available to the heater, where the product initially contained in the reservoir is aerosolized to be inhaled by the user of the aerosol-generating device.

The aerosolization module can comprise electrical contacts mounted on the second cover, the electrical contacts being adapted for electrical connection of the aerosolization module to a battery module.

The invention also relates to an aerosol generating device comprising an aerosolization module as previously described, and a battery module connected to the aerosol generating device.

The connection of the aerosolization module to a battery module forms an aerosol-generating device. The battery module is adapted to provide the aerosolization module and more particularly the heater with electricity. The battery module also generally includes a number of electronic components. These electronic components are used to control the aerosol generating system. They generally comprise a main printed circuit board assembly that carries a microprocessor. They also generally comprise a pressure sensor making it possible to determine when the user wishes the delivery of a puff by the system.

The invention also relates to a method for assembling an aerosolization module as previously described. This method comprises the steps of:

-   -   providing a reservoir, a first cover, and a second cover,     -   fitting the first cover into an opening of the reservoir, the         first cover forming a channel which extends between outside the         reservoir and an inner volume of the reservoir,     -   filling the reservoir with vaporizable material by the channel,     -   mounting the second cover on the first cover, thereby plugging         the channel with a protrusion of the second cover.

This method can further comprise a step of:

-   -   before fitting the first cover, fastening a heater assembly         comprising a heater and a heater holder to the reservoir or to         the first cover;     -   mounting electrical contacts on the second cover, the electrical         contacts being configured, once mounted on the second cover, to         provide the heater with electricity.

BRIEF DESCRIPTION OF THE DRAWINGS

Other particularities and advantages of the invention will also emerge from the following description.

In the accompanying drawings, given by way of non-limiting examples:

FIG. 1 represents, in a schematic sectional view, an aerosolization module according to an embodiment of the invention;

FIG. 2 represents, in a schematic sectional view, the aerosolization module of FIG. 1 in a configuration allowing filling of its reservoir;

FIG. 3 represents, in a schematic three-dimensional view, some parts of the aerosolization module of FIG. 1 to illustrate some aspects of the invention;

FIG. 4 represents, in a schematic diagram, a method for assembling the aerosolization module 1, as an example of a method for assembling an aerosolization module according to the invention.

DETAILED DESCRIPTION

FIG. 1 represents an aerosolization module according to an embodiment of the invention.

The aerosolization module comprises a reservoir 1. The reservoir 1 has at least one wall 2. The reservoir 1 defines an inner volume 3 that is adapted to contain a vaporizable material. The reservoir can be, by way of example, a one-piece plastic part, for example obtained by injection moulding.

The vaporizable material can be in liquid form, in solid form, or in a semi liquid form (paste, gel, wax, etc.), or in a combination thereof.

The reservoir 1 comprises an opening. The reservoir 1 can for example have a concave shape, the concavity of the reservoir forming the inner volume 3. An open face, e.g. the bottom face 4, of the reservoir 1 can form the opening of the reservoir.

The reservoir 1 is closed by a combination of two covers, namely a first cover 5 and a second cover 6.

The first cover 5 is made of a resilient material. The term resilient material should be understood in a non-restrictive manner. It designates any soft material, and/or a material that is elastic, resilient, flexible, or springy.

The resilient material is advantageously silicone. It can be any rubbery material.

The first cover can tightly cooperate with the wall 2 of the reservoir 1, at the periphery of the opening of the reservoir.

The first cover forms a channel 7 from outside the reservoir 1 to the inner volume 3 of the reservoir. This channel is plug by the second cover 6 as hereafter explained.

FIG. 2 represents the aerosolization module of FIG. 1 without the second cover 6, i.e. in a configuration in which the second cover 6 is not in place or removed. In the configuration of FIG. 2 , the channel 7 is free and makes it possible to introduce, e.g. to inject, a vaporizable material into the reservoir 1.

This configuration is thus used to fill the reservoir 1 with a vaporizable material such as an e-liquid.

As shown in FIG. 1 , the second cover 6 is configured to be mounted on the first cover. In the represented example embodiment, the second cover 6 fits in a recess that is formed in the first cover 5. The second cover 6 thus has a shape that generally corresponds to the shape of this recess. The second cover comprises a protrusion 8. The protrusion 8 is a projecting part of the second cover 6.

The protrusion 8 has a shape that corresponds to the shape of the channel 7. There is no clearance between the protrusion and the channel, so that the protrusion cooperates with the walls of the channel to form a seal. The protrusion can even be slightly wider than the channel 8, into which it enters thanks to the flexibility of the first cover 5.

The protrusion 8 can have various shapes. In the represented embodiment, it has a shape consisting of two cylinders, namely a narrower cylinder at the top and wider at the base, these cylinders being connected by a conical frustum.

The second cover 8 can be made of various materials, rigid or flexible. For example, it can be made of silicone. A second cover 6 made of silicone is easy to mount on the first cover 5, and allows a very good seal of the channel which it plugs.

It should be noted that the aerosolization module can be a consumable item. It can also be designated by the term “cartridge”. Once the vaporizable material initially contained in the reservoir has been consumed, and the reservoir is empty, the aerosolization module is replaced by another aerosolization module with a full reservoir. The old module can be discarded, preferably for recycling. A change of aerosolization module can also be carried out, even before the reservoir is empty, in order to change the product to be vaped. This allows for example the user to choose the taste of the product which he consumes.

The aerosolization module can comprise a heater to vaporize the vaporizable material (and is in such case generally called “vaporizer”), or not comprise a heater (and is in such case generally called “cartomizer”).

In the represented embodiment, the aerosolization module comprises a heater 9 that is fixed to a heater holder 10. The heater 9 and the heater holder 10 constitute a heater assembly that is rigidly fixed to the reservoir 1.

In this embodiment, the heater holder is provided with a through-hole 11.

The through-hole 11 hole is aligned with the channel formed by the first cover, so that when a vaporizable material is introduced into the reservoir 1 by the channel 7, it freely crosses the through-hole 11.

The reservoir 1 can comprise or can form, at its upper end, a mouthpiece 12. The mouthpiece is the part of the aerosol generating device where the user places his mouth to vape, i.e. to inhale the aerosolized product.

A central tube 13 connects the mouthpiece 12 to the heater 9 where the vaporizable material is vaporized. In the represented embodiment, the central tube 13 is formed by the reservoir and the heater assembly. More particularly, the central tube 13 is formed of two sections, namely a bottom section 15 formed by the heater assembly and a top section 14 formed by the reservoir. A seal 16 is interposed between the bottom section 15 and the top section 14. The seal 16 provides good and reliable fluid-tightness between the inner volume 3 of the reservoir 1 and the central tube at the junction between the bottom section 15 and the top section 14.

The heater 9 can advantageously have an elongated shape, so that it extends in the same direction as the central tube 13.

The heater 9 generally comprises an electrically resistant element, such as an electrically resistant wire that can be coiled. The heater 9 can thus be installed longitudinally in the central tube 13. Alternatively, it can be wrapped around the central tube 13. Alternatively, it can form part of the central tube (i.e. of the wall that defines the central tube 13, and more particularly its bottom section 15).

All these configurations of heater 9 are called “vertical heater”, because the heater extends in a bottom to top direction of the aerosolization module, like the central tube 13.

The heater has to be provided with liquid (or more generally with vaporizable material) present in the reservoir 1. FIG. 3 illustrates this aspect of the invention. FIG. 3 shows in a schematic three-dimensional view the aerosolization module of FIG. 1 , except that the reservoir is omitted and its position is shown only in transparency for the correct understanding of the figure.

At the base of central tube 13 (i.e. in this embodiment at the base of its bottom section, 15) which is at the bottom level of the inner volume of the reservoir that is available to contain a vaporizable product, at least one hole 17 is provided in the wall of the central tube. Advantageously, several holes 17 distributed around the central tube 13 are provided, to allow a good distribution around the heater of the product to be vaporized.

In the represented embodiment, four holes 17 are provided. In other embodiments, two, three, five, and six holes 17 are provided. A regular distribution of the holes around the central tube 13 is preferred (e.g. two diametrically opposite holes 17).

Each hole 17 allows fluid communication between the inner volume of the reservoir and the heater 9.

A porous material 18 is advantageously provided around the heater 9. It can be a cotton pad wrapped around the heater. This helps to obtain a homogeneous distribution of the vaporizable material around the heater.

The central tube 13 has to be provided with air, in which the vaporizable material is aerosolized by the heater 9. Air in which the vaporizable material is aerosolized is then inhaled by the user.

To provide the central tube 3 with air the first cover 5 and the second cover 6 define a path from outside the aerosolization module to the central tube. As the air must flow around or in the heater 9, the path issues in the central tube under the heater 9, i.e. such that the heater 9 is positioned between the outlet of the path in the central tube 13 and the mouthpiece 12. The path can issue on a lateral wall of the aerosolization module or on the second cover 6.

The aerosolization module can comprise electrical contacts 19 that are configured to provide the heater with electricity. The electrical contacts 19 can be electrical plugs configured to mate with spring pin connectors, usually called “pogo pins™”. A spring pin connector is usually made up of two sliding cylinders constrained against each other by an internal spring. Other types of electrical contact can be used, for example electrical contacts configured to cooperate with plate spring contacts.

FIG. 4 represents, in a schematic diagram, a method for assembling the aerosolization module.

This method comprises the steps of providing a heater S1. In the represented example, this step comprises assembling an electrically resistant wire 20 and a heater body 21.

The heater is then fastened to a heater holder 10 to form a heater assembly (S2). The heater holder is formed in this example of several parts: the bottom part of the central tube 15, and a main part 22.

The seal 16 can also be mounted on the top of the bottom part of the central tube 15 in this step.

A first cover is provided (in a step of providing a first cover S3) and assembled to the heater assembly (in an assembling step S4).

The method further comprises the step of providing a reservoir S5. The method then comprises a step of fitting the first cover 5 into an opening of the reservoir (S6). This implies, in the represented embodiment in which the aerosolization module comprises a heater assembly, and in which the heater assembly is fastened to the first cover, that the heater assembly is fastened to the reservoir 1 in this step.

Once the first cover is fitted into the opening of the reservoir 1, the reservoir 1 is filled with vaporizable material in a filling step S7.

A second cover is provided (in a step of providing a second cover S8)

The method then comprises a step of mounting the second cover 6 on the first cover 5 (S9). In this step, the channel of the first cover 5 is plugged with a protrusion of the second cover 6, and the vaporizable material can no longer leak from the reservoir 1.

The method can comprise a step of mounting electrical contacts 19 on the second cover 6 (S10).

An optional, final step of assembling a base 23 can be performed. The aerosolization module is complete and ready to be used.

This process is of course described by way of example. Many other embodiments, having another step order or other combinations of the steps described above, can be envisioned in the context of the present invention.

The aerosolization module developed in the invention, which comprises a reservoir that is closed by the combination of a first, resilient, cover forming a channel for product injection into the reservoir and a second cover comprising a protrusion configured to plug the channel when inserted into said channel provides an easy to fill and easy to assemble aerosolization module.

According to some embodiments of the invention, the aerosolization module can comprise vaporization means, such as a heater, with an optimized arrangement.

The invention also affords the possibility of an optimized arrangement of aerosolization module, that helps in the design of a small, appealing, and convenient vaporizer when the aerosolization module is connected to a corresponding battery module.

REFERENCES USED FOR THE FIGURES

1 Reservoir 2 Wall 3 Inner volume 4 Bottom face 5 First cover 6 Second cover 7 Channel 8 Protrusion 9 Heater 10 Heater holder 11 Through-hole 12 Mouthpiece 13 Central tube 14 Top section 15 Bottom section 16 Seal 17 Hole 18 Porous material 19 Electrical contacts 20 Electrically resistant wire 21 Heater body 22 Main part 23 Base 

1. An aerosolization module for an aerosol generating device comprising: a reservoir comprising at least one wall that defines an inner volume adapted to receive a vaporizable material, said at least one wall defining an opening, a first cover made of a resilient material, the first cover being fitted into the opening and forming a channel which extends from outside the reservoir to the inner volume of the reservoir, the channel making it possible to fill the reservoir with the vaporizable material to be aerosolized; and a second cover configured to be mounted on the first cover, the second cover comprising a protrusion configured to plug the channel formed by the first cover and thereby close the reservoir when said second cover is mounted on the first cover.
 2. The aerosolization module according to claim 1, wherein the first cover is made of silicone.
 3. The aerosolization module according to claim 1, wherein the second cover is made of silicone.
 4. The aerosolization module according to claim 1, wherein the opening is located at an opposite end to a mouthpiece of the aerosolization module.
 5. The aerosolization module according to claim 1, further comprising a heater assembly comprising a heater and a heater holder, the heater assembly being fastened to the reservoir.
 6. The aerosolization module according to claim 5, wherein the heater holder comprises a through-hole aligned with the channel formed by the first cover.
 7. The aerosolization module according to claim 6, wherein the reservoir and the heater holder form a central tube in the aerosolization module, the heater extending along the central tube.
 8. The aerosolization module according to claim 7, wherein the heater is installed in the central tube, is wrapped around the central tube, or forms a portion of the central tube.
 9. The aerosolization module according to claim 7, wherein the central tube comprises at least one lateral hole to feed the heater with vaporizable material contained in the reservoir.
 10. The aerosolization module according to claim 7, wherein the first cover and the second cover define a path for providing air to the central tube.
 11. The aerosolization module according to claim 5, wherein the heater is surrounded by a porous material, which regulates a flow of vaporizable material from the reservoir to the heater.
 12. The aerosolization module according to claim 1, further comprising electrical contacts mounted on the second cover, the electrical contacts being adapted for electrical connection of the aerosolization module to a battery module.
 13. An aerosol generating device comprising the aerosolization module according to claim 1, and a battery module connected to the aerosol generating device.
 14. A method for assembling an aerosolization module, the method comprising the steps of: providing a reservoir, a first cover, and a second cover, fitting the first cover into an opening of the reservoir, the first cover forming a channel which extends between outside the reservoir and an inner volume of the reservoir, filling the reservoir with vaporizable material by the channel, and mounting the second cover on the first cover, thereby plugging the channel with a protrusion of the second cover.
 15. The method according to claim 14, further comprising the steps of: before fitting the first cover, fastening a heater assembly comprising a heater and a heater holder to the reservoir or to the first cover; and mounting electrical contacts on the second cover, the electrical contacts being configured, once mounted on the second cover, to provide the heater with electricity. 